Fastener products

ABSTRACT

The invention relates to fastener products. In some aspects of the invention, a fastener product includes an elongate strap, projections molded of resin encapsulating features of the strap in a first region, and a head element molded of resin encapsulating features of the strap in a second region. The head element includes a hole sized to receive an end of the strap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is divisional application of U.S. patent applicationSer. No. 10/997,337, filed Nov. 24, 2004, which claims the benefit ofU.S. Provisional Patent Application Ser. No. 60/547,212, filed Feb. 24,20041 and which also claims the benefit from U.S. Provisional. PatentApplication Ser. No. 60/624,216, filed Nov. 2, 2004. The entire contentsof the aforementioned patent applications are herein incorporated byreference.

TECHNICAL FIELD

The invention relates to fastener products.

BACKGROUND

Fastener strips and other types of fastener products have long been usedto releasably attach articles to one another. They are modernly used ina vast array of commercial products ranging from automobiles todisposable undergarments. A common use for elongated fastener strips isto retain articles in a bundle. For example, fastener strips can bewrapped around groupings of wires, tubes, or other objects to hold themin an ordered bundle.

For applications like those discussed above, it is sometimes beneficialto attach a structural element to the fastener strip. For example, aD-ring is sometimes attached to a fastener strip so that a free end ofthe fastener strip may be looped through the D-ring and fastened to amore central region of the fastener strip. It is often possible tosecure the strap more tightly by using the D-ring as a leveragingdevice. As a result, bundles of material may be retained more tightly.Structural elements have occasionally been attached to fastener productsfor other uses as well.

Conventionally, such structural elements and fastener strips are formedas separate pieces and subsequently attached to one another to form theproducts discussed above. For example, fastener strips have been sewedand/or adhesively attached to structural elements.

Another type of fastener commonly used to retain articles, for example,is a zip tie. Zip ties are devices that typically include a strap and ahead element. Multiple projections extend from the strap, and the headelement defines a hole. The projections are arranged along the strapsuch that they allow the strap to be pulled through the hole in only onedirection. When the strap is pulled through the hole in the oppositedirection, the projections engage with the head element to preventfurther movement of the strap.

Conventional zip ties are typically formed using injection-moldingtechniques.

SUMMARY

In one aspect, a method of making discrete fastener products includesproviding a rotating mold roll having a peripheral surface. The moldroll defines an array of molding cavities extending inwardly from theperipheral surface. The mold roll is positioned adjacent a pressuredevice to define a pressure nip. At least one of the mold roll and thepressure device define at least one molding recess that is substantiallylarger than the molding cavities. Resin is introduced to the rotatingmold roll. The resin is pressed into the molding cavities to form amultiplicity of discrete projections, and the resin is pressed into themolding recess to form a series of discrete, longitudinally spaced apartstructural features. The projections and the structural features arecarried on a continuous sheet form base. The resin is removed from themold roll to expose a continuous preform sheet including the base, theprojections, and the structural features. The structural features arearranged along the preform sheet in a longitudinally repeating pattern.The preform sheet is separated into multiple discrete products, eachdiscrete product including an array of the projections and at least oneof the structural features.

In some cases, the molding cavities are shaped to form projections withheads overhanging the base. In some cases, the pressure device is acounter-rotating pressure roll. The pressure roll defines the moldingrecess in many cases. The pressure roll is internally cooled in somecases.

In some cases, the mold roll and the pressure device define multiplemolding recesses. The mold roll defines the molding recesses in manycases. In some cases, the molding recess comprises a groove. The grooveincludes a bottom surface, and multiple protrusions extend from thebottom surface in many cases. In many cases, the protrusions arecircumferentially spaced apart.

In some cases, the molding recess comprises a central protrusion.

In many cases, the molding recess comprises multiple discretedepressions arranged in a predetermined configuration. The depressionsare arranged in a substantially square arrangement in some cases. Thedepressions are arranged in a substantially circular arrangement inother cases.

In many cases, the molding recess is defined by the mold roll. Themolding recess comprises a continuous groove defined by the peripheralsurface of the mold roll in many cases.

In some cases, the mold roll includes an outer edge region and themolding recess extends circumferentially along the outer edge region.

In other cases, multiple molding recesses extend across a transversedirection of the mold roll.

In some cases, the molding recess is defined by an insert retainedwithin at least one of the mold roll and the pressure device. The insertis retained within the mold roll in many cases. The insert extendstransversely from a first side of the mold roll to a second side of themold roll in some cases. The insert is press-fitted within a slot in themold roll in some cases. The insert defines multiple molding recesses inmany cases.

In some cases, the resin is continuously introduced to the mold roll.The resin is introduced into the pressure nip in many eases. The resinis introduced in discrete lanes separated along a transverse directionof the mold roll in some cases.

In many cases, introducing resin to the mold roll includes extruding theresin into the pressure nip.

In other cases, introducing resin to the mold roll includes extrudingthe resin onto a sheet-form material and continuously introducing thesheet-form material and the resin into the pressure nip. The resin isextruded onto the sheet-form-material in lanes separated along atransverse direction of the sheet-form material in some cases.

In many cases, the projections comprise vertical stems extending fromthe base. The stems are depressed to form multiple flat-topped fastenerelements in some cases.

In some cases, the projections as formed include a stem portion and ahead portion, the head portion overlying the base. The head portionoverlies the base in at least one discrete direction in many cases. Insome cases, the projections have distal ends extending downward towardthe base. The head portion overlying the base in multiple directions insome cases.

In many cases, each projection comprises a wedge with an upper surfaceextending from the base at an angle of between about 5 degrees and, 45degrees and terminating in a raised distal edge. The raised distal edgeextends from the base at an angle between about 45 degrees and 90degrees in some cases. The raised distal edge extends from the base atan angle of about 90 degrees in some cases. In many cases, the wedgesare arranged in a single row along the base.

In many cases, the discrete product includes an elongated strap having afree end. Each structural feature forms a hole sized to receive the freeend of the strap in some cases. The structural features include surfacesconfigured to engage the wedges when the free end of the strap is pulledthrough the hole in some, cases. In, many cases, the structural featureis arranged at an end of the strap opposite the free end. In some cases,the raised edges of wedges are directed away from the free end of thestrap.

In some cases, the projections are fashioned to engage with other likeprojections.

In some cases, the structural features comprise surfaces defining holesextending into the sheet-form base. In many cases, the holes extendcompletely through the sheet-form base. The holes are defined by aregion of the base that is substantially thicker than the region of thebase carrying the projections in many cases. The discrete productincludes an elongated strap having a free end, and each structuralfeature forms a hole sized to receive the free end of the strap in somecases. The structural features comprise surfaces configured to engagethe projections when the free end of the strap is pulled through thehole in many cases.

In many cases, the structural features include resin surfaces extendingoutwardly from the base. The structural features form resilient fingersarranged in associated sets defining a boss sized to be received in amedia disc-mounting hole in some cases.

In many cases, the continuous sheet-form base is formed of the resin onthe mold roll. The continuous sheet-form base comprises the resin and acontinuous sheet-form material attached thereto in some cases. In somecases, the continuous sheet-form base comprises multiple lanes of resinattached to the sheet-form material, the lanes being separated along atransverse direction of the sheet-form material.

In other cases, the method further includes introducing a longitudinallycontinuous backing material to the mold roll along with the resin. Theresin is introduced in discrete regions interconnected by the backingmaterial in some cases. The discrete regions of resin compriselongitudinal bands in many cases. In many cases, the backing material islaminated to the resin under nip pressure. In many cases, the backingmaterial comprises a non-woven knit. The backing material includes afoam material in some cases. The backing material comprises a metallizedfilm in other cases. In some cases, the backing material includes fiberscapable of engaging the projections when the product is folded uponitself.

In some cases, the continuous preform sheet includes a continuous resinlayer.

In some cases, the continuous pre-form sheet includes a carrier andmultiple laterally separated resin bands.

In other cases, the continuous pre-form sheet includes lateral rows ofstructural features.

In some cases, the continuous pre-form sheet includes longitudinal bandsof projections.

In many cases, the continuous pre-form sheet includes at least onelongitudinal lane of structural features. The continuous preform sheetincludes lateral bands of projections in some cases.

In many cases, the structural features are longitudinally separated by acommon distance along the sheet.

In some cases, separating the fastener sheet includes, cutting thesheet. The sheet is conveyed through a cutter that is controlled tointermittently cut the sheet as the sheet is conveyed in many cases. Insome cases, the cutter comprises a roll having cutting blades configuredto perforate the sheet in predetermined regions. In some cases, thesheet is cut along its transverse direction. In other cases, the sheetis cut along its longitudinal direction.

In some cases, the method further includes weakening the sheet to defineboundaries along which the sheet will be separated. In many cases,weakening the sheet includes perforating the sheet in predeterminedregions. Perforating the sheet includes conveying the sheet between acutting roll and a support roll, the cutting roll having protrusionsextending from a peripheral surface in many cases.

In some cases, the method further includes spooling the sheet fortransport.

In some cases, the method further includes introducing a loop materialinto the nip, the loop material being capable of engaging theprojections when the product is folded upon itself. The loop material isintroduced into a central region of the nip in many cases.

In some cases, the method also includes, pressing the resin into asecond molding recess defined by at least one of the mold roll and thepressure device to form a second structural feature carried by thesheet-form base. In some cases, at least one of the mold roll and thepressure device define multiple second molding recesses. In someembodiments, the mold roll defines the second molding recesses. Thesecond molding recess includes a groove in many cases. In some cases,the groove includes a bottom surface, and multiple protrusions extendfrom the bottom surface. In some cases, the protrusions arecircumferentially spaced apart. The second molding recess comprisesmultiple depressions arranged in a predetermined configuration in somecases. The multiple depressions are arranged to form ribs in manyembodiments. The ribs extend longitudinally on the sheet-form base insome cases.

In some embodiments, the second molding recess is defined by the moldroll. In some cases, the second molding recess comprises a continuousgroove defined by the peripheral surface of the mold roll. In somecases, multiple second molding recesses extend across a transversedirection of the mold roll.

The second molding recess is defined by an insert retained within atleast one of the mold roll and the pressure device in some cases. Theinsert is retained within the mold roll in many cases. The insertextends transversely from a first side of the mold roll to a second sideof the mold roll in some embodiments. In some cases, the insert ispress-fitted within a slot in the mold roll. The insert defines multiplemolding recesses in some cases.

In some embodiments) the second molding recess is positioned adjacentthe first molding recess.

In some cases, the second molding recess includes multiplecircumferential channels defined by the mold roll to form longitudinallyextending ribs.

The second structural feature, in some embodiments, has a thickness atleast as great as a thickness of the first structural feature.

In another aspect, a fastener product includes an elongate strap havinga first end and a second end. An array of fastener projections is moldedof resin encapsulating features of the strap in a first region. A headelement is molded of resin encapsulating features of the strap in asecond region. The head element includes surfaces defining a hole sizedto receive the second end of the strap. A backing material ispermanently attached to and overlying a back surface of the strap.

In some cases, the strap includes a continuous resin layerinterconnecting the projections and the head element. The head has athickness greater than a thickness of the strap in many cases. The headand strap form a unitary structure of molded resin in some cases.

In some cases, the head includes a protrusion configured to engage theprojections when the second end of the strap is pulled through the holedefined by the head.

In many cases, the backing material exhibits elastic characteristics.

In some cases, at least one resin region is permanently attached to thebacking material. The projections extend from the resin region in manycases. The head is formed of resin in many cases. The stems aredepressed to form multiple flat-topped fastener elements in some cases.

In many cases, the projections include a stem portion and a headportion, the head portion overlying the strap. The head portion overliesthe strap in at least one discrete direction in many cases. The headportion has a distal end extending downward toward the strap in somecases. The head portion has multiple distal ends extending downwardtoward the strap in, some other cases. In some cases, the head portionoverlies the strap in multiple directions.

In some cases, each projection, comprises a wedge with an upper surfaceextending from the strap at an angle of between about 5 degrees and 45degrees and terminating in a raised distal edge. The wedges are arrangedin a single row along the strap in many cases. The wedges are arrangedlongitudinally along the strap in some cases. In some cases, the raisededges of the wedges are all directed away from the free end of thestrap.

In some cases, the projections are fashioned to engage with other likeprojections.

In some cases, the hole extends completely through the strap and thebacking material.

In many cases, the head element is substantially thicker than the strap.

In many cases, the backing material is laminated to the strap. Thebacking material comprises a knit material in many cases. The backingmaterial comprises a foam material in many other cases. In still othercases, the backing material comprises a metallized film. In many cases,the backing material includes fibers capable of engaging the projectionswhen the product is folded upon itself.

In some cases the backing material is attached to a first, surface ofthe strap and a loop material is attached to a second surface of thestrap.

In another aspect, a preform fastener product sheet includes acontinuous sheet-form strap. An array of projections extend from thesheet-form strap. The projections are integrally attached to the strap.Multiple structural features extend from the sheet form strap. Thestructural features are integrally attached to the strap. The strapinterconnects the structural features and the projections. The sheetincludes frangible parting lines between the regions defining multiplediscrete fastener products. Each discrete product includes at least oneof the structural features and at least one of the projections.

In yet another aspect, a method of making discrete fastener productsincludes providing a rotating mold roll having a peripheral surface. Themold roll defines an array of molding cavities extending inwardly fromthe peripheral surface. The mold roll is positioned adjacent a pressuredevice to define a pressure nip. Resin is introduced to the rotatingmold roll. The resin is pressed into the molding cavities to form amultiplicity of discrete projections. The projections are carried on acontinuous sheet-form base. The resin is removed from, the mold roll toexpose a continuous preform sheet carrying the projections. Multiple,longitudinally separated slots are created within the preform sheet. Thepreform sheet is separated into multiple discrete products. Eachdiscrete product includes an array of the projections and at least oneof the slots.

In another aspect, a fastener product includes an elongate strap havinga first end and a second end, an array of projections molded of resinencapsulating features of the strap in a first region, a head elementmolded of resin encapsulating features of the strap in a second regionand a band of resin molded of resin encapsulating features of the strapin a discrete region spaced apart from the head element. The resin bandstiffens the strap in the discrete region. The head element includessurfaces defining a hole sized to receive the second end of the strap.

In some embodiments, the strap comprises a continuous resin layerinterconnecting the projections, the head element, and the resin band.

In some embodiments, the resin band has a thickness of about 0.05 inchto 0.20 inch. The resin band and the strap form a unitary structure ofmolded resin in some cases.

In some embodiments, the fastener product also includes a loop materialattached to the strap, and configured to engage the projections. Theprojections are hooks in some cases.

In some cases, the strap comprises at least one resin region permanentlyattached to a backing material. The backing material exhibits, elasticcharacteristics in some embodiments. The projections extend from theresin region in some cases. The backing material, in some embodimentsincludes fibers capable of engaging the projections when the product isfolded upon itself. In some cases, the head element extends from theresin region. The resin band extends from the resin region in someembodiments.

In some cases, the projections comprise vertical stems extending fromthe strap. The stems, in some embodiments, are depressed to formmultiple flat-topped fastener elements.

In some embodiments, the projections, include a stem portion and a headportion overlying the strap. The head portion, in some cases, overliesthe strap in at least one discrete direction. The head portion has adistal end extending downward toward the strap in some cases. The headportion, in some embodiments, has multiple distal ends extendingdownward toward the strap. The head portion overlies the strap inmultiple directions in some cases.

In some embodiments, the projections are fashioned to engage with otherlike projections.

In some cases, the hole extends completely through the strap.

In some embodiments, the fastener product also includes a backingmaterial attached to the strap. In some cases, the backing material islaminated to the strap. In some cases, the backing material includes afoam material.

In some cases, the resin band comprises a plurality of nibs.

In some embodiments, the resin band extends transversely on the strap.

In some cases, the fastener product also includes a loop materialattached to the strap. In some embodiments, the projections comprisehooks configured to engage with the loop material.

In another aspect, a body part of a user is stabilized by providing asplint device having a strap including a substrate, a rigid supportmember extending across the strap and formed of resin solidified toencapsulate surface features of the substrate, and fastener projectionsextending from the substrate in a first region. The substrate carriesengageable loops in at least a second region. The strap is wrappedaround the body part such that the support member extends along the bodypart and is arranged to resist motion of the body part. The fastenerprojections releasably engage the engageable loops to secure the straparound the body part.

In some embodiments, the body part is aligned substantially about alongitudinal axis of the rigid support member.

In some embodiments, the body part is selected from the group consistingof a finger and a toe. In some embodiments, the body part is selectedfrom the group consisting of a plurality of fingers and a plurality oftoes.

In some embodiments, the elongate strap exhibits elastic properties.

In some cases, the fastener projections include a stem portion and ahead portion, and the head portion overlies the strap.

In some cases, the rigid support member defines a hole sized to receivea first end of the strap.

In some embodiments, the rigid support member is sufficiently rigid toresist flexion of the body part when held against the body part. In someembodiments, the rigid support member has a stiffness of at least about15 lb/in. In some embodiments, the strap has a Gurley stiffness of nogreater than about 1000 milligrams.

In some cases, the rigid support member has a thickness of about 0.050in. to about 0.200 in.

in another aspect, body parts are grouped by providing an elongate strapdefining a hole. The strap includes a substrate having a plurality offastener projections extending from a first region. The substratecarries engageable loops in at least a second region. The first andsecond body parts are inserted into the hole defined by the strap. Thestrap is wrapped about the first and second inserted body parts. Thefastener projections are releasably engaged to the engageable loops tosecure the strap about the first and second inserted body parts.

In some embodiments, the body parts are selected from the groupconsisting of fingers and toes.

In some embodiments, the elongate strap exhibits elastic properties.

In some embodiments, a third region of the strap is permanently attachedto a fourth region of the strap to define the hole. In some embodiments,the third region is bonded to the fourth region.

In yet another aspect, a splint includes an elongate, flexible strapcarrying engageable loops din a first region, an array of fastenerprojections with stems molded of resin encapsulating features of thestrap in a second region, and a rigid, stiffening band extending acrossthe strap in a discrete region thereof. The band includes resinencapsulating features of the strap in the second region. The stiffeningband is of sufficient stiffness to resist bending of a body part wrappedby the splint.

In some embodiments the strap has a Gurley stiffness of no greater thanabout 1000 milligrams, and the stiffening band has a stiffness of noless than about 15 lb/in.

In some cases, the stiffening band has a thickness of about 0.050 in. toabout 0.200 in.

In some embodiments, the splint also includes a head element molded ofresin encapsulating features of the strap in a third region, the headelement defining a hole sized to receive the strap.

In some embodiments, the splint includes a backing material attached tothe strap. In some embodiments, the backing material comprises a foammaterial.

In some cases, the strap exhibits elastic properties.

In some embodiments, the fastener projections are configured to engage,with the engageable loops to secure the splint around the body part.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a fastener strap with an integral headelement.

FIG. 1A shows the strap of FIG. 1 wrapped about a bundle of wires.

FIG. 2 illustrates a method and apparatus for producing the fastenerproduct of FIG. 1.

FIG. 3 is a perspective view of the mold roll of the method andapparatus shown in FIG. 2.

FIG. 4 is an enlarged view of area 4 of FIG. 3.

FIG. 5 is a plan view of a fastener product sheet and an; individualproduct separated, from that sheet.

FIG. 5A is a plan view of another fastener product sheet and anindividual product separated from that sheet.

FIG. 6 is a sectional view of a separating device.

FIGS. 7 and 8 illustrate alternative methods and apparatuses forproducing the fastener product of FIG. 1.

FIG. 9 is a perspective view of another fastener product.

FIG. 10 is a perspective view of a molding nip for producing thefastener product of FIG. 7.

FIG. 11 is an enlarged view of area 11 of FIG. 10.

FIG. 12 is apportion of a fastener product sheet produced by the processshown in FIG. 10, die cut to define individual products as shown in FIG.9.

FIG. 13 is an alternative fastener product.

FIG. 13A is a cross-sectional view of a fastener product similar to thefastener product shown in FIG. 13, but having a backing material.

FIG. 14 is another fastener product having alternative fastenerprojections.

FIG. 15 is a partial cross-sectional view of the fastener product shownin FIG. 13 in a fastened position.

FIG. 15A is a cross-sectional view of the head element of FIG. 13.

FIG. 15B is a partial cross-sectional view of a fastener product havinga releasable retaining arm in a fastened position.

FIG. 16 is a perspective view of an alternative fastener product havingguide rails.

FIG. 17 is a view of a molding nip for producing the fastener product ofFIG. 13.

FIG. 18 is an enlarged view of area 18 of the mold roll of FIG. 17.

FIG. 19 is a perspective view of a fastener product sheet and a productthat has been separated from that sheet.

FIG. 20 is a plan view of the fastener product sheet of FIG. 19.

FIG. 21 is a perspective view of an alternative mold roll used to makethe fastener product shown in FIG. 13.

FIG. 22 is an enlarged view of area 22 of the mold roll of FIG. 21.

FIG. 23 is a perspective view of another fastener product having a tag.

FIG. 24 is a perspective view of another fastener product having a tagwith an aperture.

FIG. 25 is a perspective view of another fastener product having a flathead.

FIG. 26 is a perspective view of a fastener product sheet formed usingthe mold roll of FIG. 21.

FIG. 27 is a row of longitudinally connected fastener products detachedfrom the fastener sheet of FIG. 26.

FIG. 28 is a top view of a splint device.

FIG. 29 is a top view of another splint device.

FIG. 30 is a perspective view of a molding device used to create thesplint device of FIG. 28.

FIG. 31 is a top view of a fastener product sheet that can be separatedto produce a plurality of the splint devices of FIG. 28.

FIG. 32 is a perspective view of another splint device.

FIG. 33 is a perspective view of a molding device used to create thesplint device of FIG. 32.

FIG. 34 is a partial top view of a fastener product sheet that can beseparated to produce a plurality of the splint devices of FIG. 32.

FIG. 35 is a perspective view of another splint device.

FIG. 36 is a top view of another fastener product.

FIG. 37 is a top view of a fastener product sheet that can be separatedto produce a plurality of the fastener products of FIG. 35.

Like reference symbols in the various drawings, indicate like elements.

DETAILED DESCRIPTION

Referring to FIG. 1, a fastener product 100 includes an elongatefastener strap 105, a head element 110, and a backing material 112. Thefastener strap 105 is adapted to cooperate with the head element 110such that the fastener product 100 can be wrapped around a group ofarticles and fastened to retain the articles in a bundle, as shown inFIG. 1A, for example. Other uses are also contemplated. As discussed inmore detail below, a continuous molding process can be employed toproduce the fastener product 100 and other fastener products havingfastener elements and structural features extending from a base.

The fastener strap 105 includes a continuous resin base 115 permanentlyattached to the backing material 112. Multiple fastener elements orhooks 130 extend from the resin base 115 in first fastening regions 120,122 and multiple fastener elements or loops 135 extend from the base 115in a second fastening region 125. The hooks 130 in this case, aredesigned to engage the loops 135 to provide fastening ability.Therefore, when the fastening strap 105 is folded over upon itself suchthat one of the first regions 120, 122 is brought into contact with thesecond region 125, the hooks 130 engage the loops 135 to retain thefastener strap in the folded position.

The first fastening regions 120, 122 and the second fastening region 125can be positioned at various different locations of the strap. Forexample, the first regions can be located at a central portion of thestrap and the second region can be located at the end portion. In someembodiments, the strap can include hooks on the first region 120 and thesecond region 125.

The fastener elements 130 in the first regions 120, 122 are J-shapedhooks and the fastener elements 135 in the second, region 125 are loops,extending from a loop material 140 that is attached to the base 115. Thefastener elements 130, alternatively, can be any suitably shaped elementcapable of engaging the fastener elements 135, and vice versa. In otherembodiments (not illustrated), the fastener elements 130 are,mushroom-shaped elements, flat-top-shaped elements, stem-shapedelements, or loops, for example. Similarly, rather than being loops, thefastener elements 135 can be hooks, mushroom-shaped elements, flat-topshaped elements, or stem-shaped elements, for example. In someembodiments, the fastener elements 130, 135 can be of like shape suchthat they are configured to engage one another. These types of fastenerelements are commonly known as self-engaging fastener elements. Commonexamples of male self-engaging fastener elements include mushroom-shapedelements. Although, other forms of self-engaging fastener elements arealso contemplated.

The resin base 115 extends continuously along the fastener strap 105.The head element 110 is, molded of resin and formed integrally with theresin base 115 of the fastener strap 105. In other embodiments, theresin base 115 can include discrete lanes of resin attached to thebacking material 112 in spaced apart regions. In such cases, the headelement 110 can be attached to the strap 105 by the backing material112, rather than being integrally formed with the resin base 115 of thestrap 105.

The head element 110 is substantially thicker than the fastener strap105. As a result, the fastener strap 105 is much more flexible than thehead element 110. This flexibility allows the fastener strap 105 to bewrapped around objects. It further allows the strap 105 to be bent orfolded over upon itself. Due to the thickness of the head element 110,it is capable of resisting relatively strong forces imparted by thestrap without bending or breaking.

The head element 110 defines an aperture or hole 145 sized to receive afree end 155 of the fastener strap 105. The hole 145 extends from a topsurface of the head 110 completely through to the bottom surface. Thefree end of the fastener strap 105 can be pulled through the hole 145.After being inserted through the aperture 145, the fastener strap 105can be folded upon itself such that the hook-shaped fastener elements130 of region 120 engage the loops 135 to fasten the strap 105 aroundthe head element 110. This allows the product 100 to form a securedenclosure around a group of articles to retain the articles in a bundle,for example.

In some embodiments, the fastener strap has a width between about 0.5inch (1.27 cm) and 2 inches (5.08 cm), and a length between about 5inches (12.7 cm) and 36 inches (91.44 cm). The head typically has awidth that is between about 0.01 inch (0.025 cm) and 0.02 inch (0.051cm) greater than the width of the strap. Thus, in many embodiments, thewidth of the head is between about 0.52 inch (1.321 cm) and 2.02 inches(5.131 cm). The cross-sectional area of the structure defining many headelements is rectangular having a thickness or height of about 0.125 inch(0.318 cm) and a width of about 0.25 inch (0.635 cm).

The strap and head element dimensions discussed above are merely used todescribe particular embodiments. Straps and head elements of variousother shapes and sizes can be produced. The head elements can be formedto be rectangular, square, triangular, circular, elliptical, or D-ringshaped, for example. Similarly, the cross-sectional area of thestructure that defines the head element can be square, rectangular,circular, or elliptical, for example. In some cases, a relatively flattab can be molded to extend from the head element to allow the user toidentify the contents retained by the product, for example. The tab canalso be equipped with an aperture to allow the user to hang the productfrom a nail or hook, for example. In some cases, the head element caninclude multiple apertures. For example, the head element can includetwo apertures separated by a cross-bar such that the strap can be loopedaround the cross-bar. Furthermore, the aperture or apertures within thehead element can be of various shapes and sizes.

In many embodiments, the head element 110 and the fastener strap 105 (orthe base 115 attached to the fastener strap 105) are formed from thesame thermoplastic material. Suitable thermoplastic materials include,for example, polypropylene, polyethylene, and polyamides. It iscontemplated that the head 110 and the fastener strap 105 can be formedof other suitable materials.

The backing material 112 is permanently attached to a bottom surface ofthe strap 105 opposite the surface from which the hooks 130 and loops135 extend. More specifically, it is permanently attached to thecontinuous resin base 115 of the strap. It is also attached to a bottomsurface of the head element 110. During use the backing material, ratherthan the resin base 115, contacts the article about which the fastenerproduct 100 is wrapped. The backing material 112 can be one of varioussuitable materials including, for example, non-woven knit, foam, andmetallized film.

The backing material 112 can serve multiple different purposes. Forexample, the backing material 112 can add support and strength to theresin base 115 from which the fastener elements 130) 135 extend. In someembodiments, as noted above, the resin base 11 includes multiplediscrete lanes of resin attached to the backing material 112, ratherthan a continuous sheet or layer of resin. The backing material 112 actsas a substrate interconnecting the discrete resin lanes and the headelement 110 in such cases. The backing material 112 can be any ofvarious suitable materials including, for example, elastic non-wovenmaterials, elastic knit materials, thermoplastic elastomers, andthermoplastic urethanes. This can result in a stretchable strap, whichcan improve fastening or retaining ability of the product 100. It is notnecessary for the backing material 112 to exhibit elasticcharacteristics. In some embodiments, the backing material 112 thatinterconnects the lanes of resin can be one of various suitable loopmaterials. In those cases, it would be unnecessary to laminateadditional loop material to the strap. When the strap is folded uponitself, its hooks could engage the loop material that is exposed betweenthe lanes of resin to enclose the strap in the fastened position.

The backing material can also help to prevent the product 100 fromcausing damage to the article that is being retained. The foam backingmaterial can be especially beneficial when the fastener product 100retains a delicate object or objects. More specifically, the foammaterial can help to ensure that the object or objects are not scratchedor otherwise damaged. Many non-woven and knit materials can provide thesame effect. The metallized film can be useful when electrical wires158, for example, are bundled together, as in FIG. 1A. In such a case,the metallized film can act to collect and ground fields about theconductors, to dissipate stray eddy currents. For example, themetallized film or other conductive substrate on the back of the strapcan conduct eddy currents directly into a grounding wire 160 of thebundle, or through a grounding cable clipped to the exposed end 155 ofthe strap.

In some embodiments, the backing material 112 can be attached only tothe strap 105 and not the head element 110. In other embodiments, theproduct can include no backing material.

Referring again to FIG. 1A, during use, the fastener strap 105 iswrapped around a group of articles and a free end 155 of the fastenerstrap 105 is inserted through the aperture 145. The fastener strap 105is then pulled through the aperture 145 to bundle the group of articles.The fastener strap 105 is then folded over upon itself such that thehooks 130 of region 120 are brought into contact with the loops 135 torestrain the fastener strap 105 from slipping back through the aperture145. This in turn insures that the group of articles remains securelybundled.

In order to release the bundle of articles 50, the fastening process isreversed. The hooks 130 are disengaged from the loops 135 by pulling thefree end 155 of the strap 105 away from the bundle of articles. The freeend 155 of the strap 115 is then pulled back through the aperture 145such that the fastener product 100 once again assumes the position shownin FIG. 1. This causes the bundle of articles 50 to be released.

Other uses are contemplated for the product 100. For example, it can bewrapped around both an article and a beam to suspend the article fromthe beam. The product 100 can be constructed to withstand multiple uses.Alternatively, it can be constructed in such a way that requires itsdisposal after each use.

FIG. 2 illustrates a method and apparatus 200 for making theabove-described fastener product 100. The apparatus 200 includes anextruder 205, a roll 210 of loop material 140, a roll 212 of backingmaterial 112, a mold roll 215, a counter-rotating pressure roll 220, astripping roll 225, and a separating device 245. The extruder 205extrudes a sheet of resin 230 into a pressure nip 235 formed between aperipheral surface of the mold roll 215 and the pressure roll 220. Atthe same time, the loop material 140 and the backing material 112 areintroduced into the pressure nip 235. The resin 230, the backingmaterial 112, and the loop material 140 are then conveyed around themold roll 215 toward the stripping roll 225. The stripping roll 225strips the resin 230, the loop material 140, and the backing material112 from the mold roll 225 to expose a continuous fastener product sheet240. The fastener product sheet 240 is then conveyed through aseparating device 245 where it is separated into multiple, discretefastener products 100 having hook regions and loop regions.

The extruder 205, as noted above, extrudes a sheet of molten resin 230into the pressure nip 235. A die can be attached to the outlet of theextruder to affect the manner in which the resin is extruded. Forexample, the die can include a continuous slot that allows the resin tobe extruded in a continuous sheet. Alternatively, the die can includemultiple discrete slots causing the resin to be extruded in multiplediscrete lanes.

The molten resin 230 can be one of various suitable materials capable ofbeing molded and retaining the molded shape. Suitable materials include,for example, thermoplastic materials, such as polypropylene,polyethylene, and polyamides. Furthermore, different materials can beintroduced into different areas of the nip 235 depending on the desiredfastener product characteristics. For example, if it is desired toproduce a product having a head element and fastener projections thatembody different physical characteristics (e.g., rigidity, hardness,etc.), then different materials can be introduced to the correspondingregions of the mold roll responsible for forming the head elements andthe fastener projections.

Referring to FIGS. 3 and 4, them old roll 215 defines multiple moldingcavities 252 and molding recesses 250. The molding recesses 252 arelocated near the edge regions of the mold roll 215. The molding cavities252 are positioned adjacent the molding recesses 250 nearer a centralportion of the mold roll 215. The molding cavities 252 are hook-shaped.Therefore, when resin is introduced into the cavities 252 and cooled,the multiple hook-shaped fastener elements 130 are molded. The cavities252 can be restricted to desired regions of the mold roll 215. Forexample, regions of cavities can be circumferentially separated alongthe mold roll by flat regions to produce alternating regions ofprojections and flat base regions. The molding recesses 250 arerectangular and each has an unrecessed center portion. Thus, when resinis introduced into the molding recesses 250 and allowed to cool, themultiple rectangular structural features or head elements 110 havingrecessed center portions are molded. Each of the molding recesses 250 isspaced along the circumferential surface of the mold roll 215 in orderto form the molded head elements 110, which are longitudinally separatedalong the fastener product sheet 240 or which define holes 145 that arelongitudinally separated along the fastener product sheet 240.

In other embodiments, the molding cavities 252 and the molding recesses250 can be of various other shapes and sizes. For example, the moldingcavities 252 can be hook-shaped, mushroom-shaped, stem-shaped, or othersuitable shapes depending on the desired shape of the projection to bemolded. The molding recesses 250, which are typically larger than themolding cavities 252, can be square, oval, circular, or other shapesdepending on the desired shape of the structural feature to be molded.

Referring again to FIG. 2, the pressure roll 220 has a substantiallysmooth peripheral surface (i.e., no protrusions or recesses). In othercases, the pressure roll can include protrusions to facilitateconveyance of the resin 230 and backing material 112 through thepressure nip 235 (i.e., the region between adjacent peripheral surfacesof the rolls), for example. The mold roll 215 and pressure roll 220 arepositioned adjacent one another with their axes of rotation X and Y,respectively, substantially aligned. As a result of the rotation andalignment of the rolls 215, 220, a large amount of pressure is createdin the pressure nip 235. When the resin 230 is introduced into thepressure nip 235 the pressure forces some of the resin 230 into themolding recesses 250 and the molding cavities 252 to form the headselements 110 and the fastener projections 130, respectively. Theremainder of the resin 230 is compressed between the peripheral surfaceof the mold roll 215 and the pressure roll 220 to form the resin base115 (shown in FIG. 1). As noted above, the resin base 115 interconnectseach of the fastener projections 130 and the head elements 110 in thisembodiment (i.e., each of the fastener projections and the head elementsextend from the common resin base).

The thickness of the base 115 depends on the separation distance betweenthe peripheral surface of the mold roll 215 and the pressure roll 220,among other things. Typically, the thickness of the base 115 increasesas the separation distance between the mold roll 215 and pressure roll220 increases. Because the desired thickness of the base 115 variesdepending on the intended use of the product, the desired separationdistance between the rolls 215, 220 can vary.

In some embodiments, as discussed below, the pressure roll 220 caninclude molding cavities and/or molding recesses in addition to orinstead of the mold roll 215. As a result, fastener products can beproduced that include fastener projections 130 and structural elements110 extending from one or both sides of the base 115. Alternatively,fastener products can be produced having one of the fastener projections130 and the structural elements 110 extending from one surface and theother extending from the opposite surface.

Referring again to FIG. 2, the loop material 140 is also introduced intothe pressure nip 235 along with the resin 230 and the backing material112. The loop material 140 is introduced to a central region of the moldroll 215 to avoid impeding the flow of the resin 230 into the moldingcavities 252 and the molding recesses 250, which are located nearer theouter edge regions of the mold roll 215. In other embodiments, themolding cavities and recesses can be located in various other positionsalong the mold roll 215 or pressure roll 220. In those embodiments, theloop material 140 can be introduced to the nip 235 along regions of themold roll 215 and pressure roll 220 that include neither cavities norrecesses.

The loop material 140 can be any of various suitable materialsincluding, for example, non-woven materials and knit materials, such asVELCRO BRAND loops 3610 and 3905. Alternatively, any suitable loopmaterial capable of engaging the hooks or other forms of fastenerelements can be used. The pressure within the hip 235 can be adjusted tolaminate the loop material 140 to the resin base 115. In otherembodiments the loop material 140 can be attached to the base 115 usingother suitable methods including, for example, adhesively attaching theloop material 140 to the resin base 115. Other details of controllinglamination of loop material to resin in the nip can be found in U.S.Pat. No. 6,202,260, the entire contents of which are incorporated byreference herein.

In some embodiments, no extra loop material is introduced into the nip135. For example, in certain cases in which the base 115 includesmultiple lanes of resin, the backing material 112 can function as theloop material. For example, the backing material 112 can be exposedbetween the lanes of resin, which assuming the backing material 112 isan engageable material, allows the fastener elements 130 to engage withthe backing material when the strap 105 is folded upon itself. In othercases, as noted above, the strap can include self-engaging fasteners. Noloop material is required in such cases.

The stripping roll 225 is configured to rotate in a manner that stripsthe resin fastener projections 130 and head elements 110 from themolding cavities 252 and molding recesses 250, respectively. At the sametime, the stripping roll 225 strips the resin base 115 from theperipheral surface of the mold roll 215. By doing this, the strippingroll 225 exposes the continuous fastener product sheet 240. The rotationof the stripping roll 225 also helps to convey the continuous fastenerproduct sheet 240 toward the separating device 245.

Referring to FIG. 5, the continuous fastener product sheet 240 includesa central portion 255 and two end portions 260, 265. The lane of loopmaterial 140 extends longitudinally along the central portion 255.Similarly, the two lanes of fastener projections 130 extendlongitudinally along the sheet nearer the end portions 260, 265. Thelanes of loop material 140 and fastener projections 130 extendsubstantially parallel to one another. The end portions 260, 265 eachinclude multiple, longitudinally spaced structures or head elements 110defining holes or apertures 245. Each of the head elements 110 islongitudinally separated by the free ends 155 of the straps. Althoughthe sheet 240 is a unitary sheet of material, transverse lines have beenincluded in order to demarcate the regions where the separating device245 (shown in FIG. 2) separates the sheet 240 to form multiple, discretefastener products 100 (shown in FIG. 1).

Referring to FIG. 6, the separating device 245 includes a cutting roll247 positioned adjacent a support, roll 249. The cutting roll 247includes multiple cutting projections 251 extending from its peripheralsurface. As the fastener product sheet 240 is conveyed between thecutting roll 247 and the support roll 249, the cutting projections 251puncture or perforate the sheet 240 along predetermined boundaries toseparate the fastener product sheet 240 into multiple, discrete fastenerproducts. The cutting roll can also be provided with blades positionedto remove any resin flash extending into or covering the aperturesthrough the head elements if needed. The support roll 249 provides asupport surface for the sheet 240 as the projections 251 are pressedinto the sheet 240. The support roll 249 can also be configured to helpconvey the sheet 240. In some embodiments, the cutting roll 247 can bepositioned adjacent the stripping roll such that the stripping roll actsas the support roll 249.

Various suitable means can be used to adapt the cutting roll 247 toperforate the sheet 240 along the predetermined boundaries. For example,the cutting roll 247 can include multiple recesses that mate with thehead elements 110 of the fastener product sheet 240. The roll 247 can beconfigured such that it includes no independent means of rotation.Therefore, the roll 247 relies on the conveyed sheet 240 to cause it torotate as the conveyed head elements 110 enter the recesses of the roll247. The projections 251 can be separated along the peripheral surfaceof the roll by a distance equal to the desired width of the discretefastener products. Thus, as the cutting roll 247 rotates, it divides thesheet 240 into multiple discrete fastener products having the desiredwidth. Other means for adapting the cutting roll 247 to cut the fastenerproduct sheet along predetermined regions are also contemplated.

Alternatively, the mold roll can be configured to mold alignmentfeatures along an outer edge or edges of the fastener sheet. Thealignment features can be arranged to mate with apertures or recesses inthe cutting roll 247 to both convey and align the sheet relative to thecutting roll. Because the alignment features are not desired features ofthe molded fastener products, they can be removed from the sheet afteror while the sheet is conveyed through the cutting roll. For example,the sheet can be conveyed through a cutting device, such as a knife,that cuts off the edge or edges of the sheet. For more detail regardingthis process, the reader is referred to U.S. Pat. No. 6,280,670, theentire contents of which are incorporated by reference herein.

Various other suitable separating devices can be used. For example, theseparating device can include one or more knives. The knives of theseparating device can intermittently cut through the sheet as the sheetis conveyed through the separating device, to produce discrete fastenerproducts. The rate at which the knives cut is dependent upon the desiredwidth (or length) of the discrete fastener products and the rate atwhich the sheet is conveyed. As another alternative, the sheet can beconveyed through a punch press device. The punch press device can beadapted to cut one or more products in a single pressing action. As withthe knives discussed above, the rate at which the punch press isactivated is dependent upon desired size of the discrete fastenerproducts and the rate of speed at which the sheet is conveyed.

After being perforated, the sheet 240 can be spooled onto a roll forshipping or storage, for example. The perforated sheet can easily beseparated by hand, for example, into multiple discrete fastenerproducts. Alternatively, the cutting roll 247 can be configured to cutthrough the entire sheet 240 to simultaneously produce the discretefastener products. For example, the cutting projections 251 can beconfigured to extend across the entire width of the fastener sheet 240.

As noted above, the cavities can be arranged along the mold roll suchthat cavity regions of the mold roll are separated by flat regions ofthe mold roll. As a result, a fastener product sheet having projectionregions separated by flat base regions can be produced. Asianalternative, a sheet having continuous regions or lanes of projections,such as the sheet shown in FIG. 5, can be conveyed through a smoothingapparatus that heats and flattens specific areas of the projectionregions to produce flat base regions. As a result of either technique, afastener sheet can be produced to have multiple, discrete fastenerproducts aligned in discrete regions, separated by a relatively flatbase. Referring to FIG. 5A, for example, the discrete fastener productscan be created to include projections 130 near their free ends 55, butnot near their head elements 110.

FIG. 7 illustrates an alternative method and apparatus 300 for formingfastener products. The method and apparatus 300 is similar to the methodand apparatus described above with respect to FIG. 2. However, ratherthan including hook-shaped cavities, the mold roll 215 includesstem-shaped cavities 252. Therefore, the fastener product sheet 240 isformed to include straight stem-shaped projections 130 that do not, asmolded, overhang the product sheet for loop engagement. The apparatusalso includes a pair of forming rolls 270, 275. The fastener sheet isconveyed between the forming rolls 270, 275 causing the rolls 270, 275to deform the stem-shaped projections 130 to form mushroom-shapedprojections. The stems 130 can also be heated prior to being conveyedbetween the forming rolls 270, 275 in order to facilitate the formingprocess. The resulting fastener product sheet 240 and the resultingdiscrete fastener products 100 include mushroom-shaped fastenerelements.

FIG. 8 illustrates another method and apparatus 800 capable of producingfastener products similar to the product shown in FIG. 1. The method andapparatus 800 is similar to the method and apparatus shown in FIG. 2.The extruder 205, however, includes an arcuate housing 280 positionedadjacent the mold roll 215 to define a gap 285 between the housing 280and the peripheral surface of the mold roll 215. The extruder 205extrudes resin into the gap 285. Due to the configuration of theextruder housing 280 relative to the mold roll 215, a large amount ofpressure is developed within, the gap 285. Due to the pressure withinthe gap 285, the resin is pressed into the molding cavities 252 andmolding recesses 250 of the mold roll to form fastener projections 130and head elements 110, respectively. In this embodiment, the backingmaterial 112 is introduced to the resin on the mold roll 215 at a pointbeyond the gap 285, but where the resin is still soft enough forlamination. In other embodiments, the backing material can be introducedto the gap 285 along with the resin. In such a case, it is preferredthat the backing material 112 be a porous material such that the resinis allowed to pass through the backing material 112 and into thecavities 252 and recesses 250 of the mold roll 215. The loop material140 is introduced to the gap 285 in a region where the mold rollcontains no recesses 250 or cavities 252. The resulting fastener productis substantially identical to the fastener product shown in FIG. 5.

Referring to FIG. 28, a splint device 1000, which can be produced usingmethods and apparatus similar to those described above, includes straps105, head elements 110, a backing material 112, and a support member1013. During use, the support member 1013 can be positioned along auser's finger or toe to provide support, for example. While in thisposition, the straps 105 can be looped through the apertures defined bythe head elements 110, and the hooks 130 can engage the loop material140 in order to securely fasten the straps 105 around the user's fingeror toe. This configuration helps to prevent the user's finger or toefrom bending substantially.

The straps 105, the head elements 110, and the backing material 112accord with the various embodiments discussed above. In the embodimentshown, each of the straps 105 includes a continuous resin base 115 thatcovers substantially the entire surface of the backing material 112.However, as discussed above, the straps can comprise discrete lanes ofthe resin base interconnected by the continuous backing material.Similarly, the straps 105 can be formed without the backing material.

In the embodiment shown, each of the straps includes a region of loopmaterial 140. However, in other embodiments, the straps 105 can beformed without the loop material. The backing material 112 can, forexample, be configured to engage the hooks 130. Similarly, rather thanincluding a region of loop material and a region of hooks, the straps105 can include two regions of self-engageable fastener elements.

The support member 1013 can be a substantially rigid memberapproximately sized to fit the finger or toe of the user. In the shownembodiment the support member 1013 is a band of resin extending acrossthe straps 105. The support member 1013 has a longitudinal extent (i.e.,an extent in the transverse direction of the straps) that is greaterthan its lateral extent (i.e., its extend in the longitudinal directionof the straps). The support member 1013 can have stiffness sufficient tosubstantially prevent the user's finger or toe from bending when thesplint 1000 is properly applied to the finger or toe. For example, thesupport member 1013 can have a stiffness of at least about 15 lb/in.(e.g., at least about 50 lb/in., at least about 100 lb/in., at leastabout 500 lb/in.), as measured using a three-point bending test withsupports spaced about one inch apart. In some embodiments, the supportmember 1013 is formed of a thermoplastic material or composition thathas a Modulus of Elasticity of about 200,000 psi or greater (e.g., about300,000 psi or greater, about 400,000 psi or greater about 500,000 psior greater).

The dimensions of the support member 1013 depend, in part, on thematerial used to construct the support member 103. The thickness of thesupport member 1013, for example, can decrease as the rigidity orstiffness of the material used to form the support member 1013increases. The support member 1013 can have a thickness of between about0.050 in. (0.127 cm) and about 0.200 in. (0.508 cm). The width of thesupport member 1013 can range from about 0.15 in. (0.381 cm) to about0.75 in. (1.905 cm).

In some embodiments, the head element 110, the base 115, and the supportmember 1013 are formed from the same thermoplastic material. Suitablethermoplastic materials include, for example, polypropylene,polyethylene, and polyamides. Other suitable thermoplastic materials canalso be used. In other embodiments, the head element 110, the base 115,and the support member 1013 can be formed from different thermoplasticmaterials.

The backing material 112 is attached to an, underside of the straps, 105and the support member 103. The backing material 112 can be a materialthat is softer than the support member 1013 and/or the strap 105, suchas foam or cloth. As a result, the backing material 112 can provide theuser with greater comfort. Various other materials can similarly beapplied to the support member 1013 to achieve various differentpurposes. Furthermore, in some cases, the splint device 1000 includes nobacking material.

The splint device can include more or less than two straps and headelements. For example, as shown in FIG. 29, a splint device 1050includes only one strap 105 and one bead element 110. The splint device1050 can be similar to the splint device 1000 in all other respects.

FIG. 30 shows the mold roll 215 that can be used with any of the variousprocesses described above to create the splint devices 1000,1050. Themold roll 215 includes a molding recess 257 in addition to the moldingrecess, 250 and the molding cavities 252. The molding recess 257receives resin to mold the support member 1013 (shown in FIGS. 28 and29). In the embodiment shown, the molding cavity 257 extendscontinuously along the circumference of the mold roll 215 in a centralregion of the mold roll 215. However, the molding cavity 257 can belocated at different regions of the mold roll 215, depending on thedesired location of the support member 1013 along the strap 105 (shownin FIGS. 28 and 29). Similarly, the molding cavity 257 can becircumferentially discontinuous to, form discontinuous support members1013. In other embodiments, as described above, the molding recess 250,the molding recess 257, and/or the molding cavities 252 canalternatively or additionally be included in the pressure device, asdiscussed above.

As shown in FIG. 31, the molding processes noted above can produce afastener product sheet 1100. Using any of the various suitable methodsdescribed above, the fastener product sheet 1100, for example, can beseparated into multiple splint devices. In particular, the fastenerproduct sheet 1100 can be separated along the dotted lines to createmultiple splint devices like the one shown in FIG. 28. The fastenerproduct sheet 1100 can alternatively or additionally be cut to createsplint devices like the one shown in FIG. 29. Upon being separated, theseparated or removed portions of the fastener product sheet 1100 thatare not included in the splint device can be discarded.

Referring to FIG. 32, a splint device 1400 includes a strap 1405, headelements 1410, a backing material 1412, and support members 1413. Thestrap 1405 call be wrapped around a user's finger or toe, for example,and narrower portions 1407 of the strap 1405 can be looped through theapertures defined by the head elements 1410. The portions 1407 of thestrap 1405 can then be secured to engageable regions of the strap byhook and loop elements, for example. This configuration helps preventthe user's finger or toe from bending substantially.

The strap 1405, can be similar to the straps discussed above. In thisembodiment, the strap 1405 includes a continuous resin base 1415. Thehead elements 1410, the support members 1413, and projections or hooks1430 extend integrally from the base 1415. A loop material 1440 isattached to the base 1415. In other embodiments, the strap 1405 caninclude discrete regions of resin that are interconnected by the backingmaterial 1412. In those embodiments, the head elements, the supportmembers, and the hooks, for example, can extend from the discrete resinregions.

As noted above, the strap 1405 includes two narrow portions 1407 at theend opposite the head elements 1410. The narrow portions, 1407 are sizedto fit within the apertures, 1445 defined by the head elements 1410 toallow the narrow portions 1407 of the strap 1405 to be looped throughthe head elements 1410 and secured to an engageable region of the strap.For example, the hooks 1430 can engage the loops of the loop material1440 to secure the straps around the user's finger or toe, as notedabove.

The support members 1413 are bands of resin extending across the strap1405. The support members 1413 include ribs 1414 that extendtransversely across the strap. The ribs 1414 help to provide the splint1400 with flexibility while maintaining a sufficient amount of rigidityto prevent the user's finger or toe from bending substantially. In otherembodiments, the support members 1413 can merely include a relativelyflat region of raised material. In certain embodiments, the supportmembers have a stiffness of at least about 15 lb/in. (e.g., at leastabout 50 lb/in., at least about 100 lb/in., at least about 500 lb/in.),as measured using a three-point bending test with supports spaced aboutone inch apart. Similarly, the splint can include more or less than twosupport members in other embodiments.

The backing material 1412 is attached to a surface of the strap 1405. Inthis embodiment, the backing material 1412 is a foam material that,during use, provides the user with added comfort. However, the backingmaterial 1412 can be any of various suitable materials. For example, thebacking material can be rubber, cloth, metal, or any of various othermaterials.

FIG. 33 shows a mold roll 215 that can be used to form the variousfeatures of the splint 1400 using any of the various techniquesdescribed above. As shown, the mold roll 215 includes molding recesses253 that extend circumferentially around the mold roll 215. The moldingrecesses 253, for example, can be grooves extending inwardly from theperipheral surface of the mold roll 215. In some embodiments; the grooveextends in a continuous fashion around the mold roll 215. The moldingrecesses 253 can mold the support members 1413 of the splint 1400 (shownin FIG. 32). In some embodiments, the molding recesses can extendtransversely across the mold roll 215. In certain embodiments themolding recesses 253 and/or any of the other mold roll features canalternatively or additionally be included in the pressure device.

Referring to FIG. 34, the methods described above can be used to form afastener product sheet 1500. The fastener product sheet 1500 can beseparated along the dotted lines provided using any of the varioustechniques described above to create multiple splint devices like theone shown in FIG. 32. The fastener product sheet 1500 can similarly beseparated to form other types of splint devices. For example, thefastener product sheet 1500 can be separated to form splint deviceshaving one or more straps and one or more head elements. In theembodiment shown, only the regions 1502 at the left side of the fastenerproduct sheet are removed to form the narrow strap portions.

As shown in FIG. 35, another splint device 1600 includes a strap 1605and a head element 1610. The splint device 1600 is similar to the strapshown in FIG. 1 and can be constructed using any of the various toolsand techniques described above. As shown, the strap 1605 can be loopedthrough an aperture 1645 of the head element 1610. The strap can then befolded upon itself and secured in a looped position. This configurationcan help, to stabilize an injured finger or toe, as discussed below.

The strap 1605 includes a support or backing material 1612, projectionsor hooks 1630, and a loop material 1640. The backing material 1612, inthis embodiment, is a stretchable cloth material. However, any of thematerials described above can be used.

In this embodiment, the hooks 1630 integrally extend from a discreteresin region 1615 that is permanently affixed to the backing material1612. The hooks 1640 can be created using any of the techniquesdescribed above. The loop material 1640, in this embodiment, ispermanently attached to the backing material 1612 in a desired region.The loop material 1640 can be attached to the backing material 1612using any of the methods described above, such as bonding and/oradhesive.

In some embodiments, a continuous resin base can be attached to thebacking material 1612. In those embodiments, the hooks 1630 and the loopmaterial 1640 can, for example, be fixed to the backing material 1612via the resin base.

The head element 1610 can be formed using any of the various methodsdescribed above.

During use, the user inserts the strap 1605 through the aperture 1645 ofthe head element 1610 to create a loop, as shown in FIG. 35. An injuredand an uninjured finger or toe are inserted into the loop. The strap isthen pulled tightly and folded upon itself such that the hooks 1630engage with the loops of the loop material 1640 to secure the strap inthe looped configuration. The strap 1605, which is securely fastenedabout the user's fingers or toes helps to stabilize the user's injuredfinger or toe by, for example, preventing it from bending substantially.The user can alternatively secure only the injured finger or toe withthe splint device 1600.

In some embodiments, the splint device 1600 need not include a headelement. For example, one end of the strap can be permanently attachedto a more central region of the strap to form a loop. Much like thesplint device shown in FIG. 35, the user's fingers or toes can beinserted through the pre-formed loop, and then the strap can be tightlywrapped around the fingers or toes of the user and secured to itself byfastening elements, for example. In this configuration, the splintdevice can similarly provide support for the user's injured finger ortoe.

Methods and apparatuses similar to those described above can also beused to produce other types of fastener products. Referring to FIG. 9,for example, a fastener product 500 includes a resin base 515 having anarray of male fastener elements or hooks 530 extending from one surfaceof the base 515 and a snap feature 510 extending from the oppositesurface of the base 515.

The snap feature 510 includes multiple arcuate ridges extending from thebase 515. The ridges are arranged to fit snugly within the mounting holeof a media disc (e.g., a compact disc) to retain the disc to the product500. In other embodiments, the snap feature 510 can be any of varioussuitable shapes and sizes. For example, the snap feature can includecylindrical pillars, resilient fingers, or similar engageablestructures. As with the product 100 discussed above, the fastenerelements 530 can be of any suitable shape capable of engaging anothermaterial. For example, they can be mushroom-shaped elements orflat-top-shaped elements.

During use, the user presses the side of the fastener product 500 thathas fastener elements 530 against an upholstered surface, for example,such that the fastener product 500 becomes releasably fastened to thesurface. The user then presses the disc against the fastener product 500such that the mounting hole within the disc is aligned with the snapfeature 510. The user can apply enough force so that the snap feature510 extends through the aperture of the disc and retains the disc to theproduct 500. The result is that the CD is suspended from the upholsteredsurface (e.g., the upholstered ceiling of a vehicle). Accordingly, thedriver and passengers are afforded easy access to the compact discswithout cluttering the vehicle.

Fastener products similar to product 500 can be produced for other usesas well. Rather than fastening the fastener elements, of the product toa fixed surface, the snap feature can be snapped into a hole defined ina fixed object such that items can be releasably fastened to the productvia the fastener elements. For example, a panel for an automotiveinterior or exterior can be molded using the process described above.The snap feature can be retainably fastened within a hole in the vehicleto secure the panel to the vehicle while exposing the fastener elementson its opposite side. Other materials (e.g., upholstery) can then befastened to the fastener elements of the panel.

For further information regarding the product 500 and similar products,the reader is referred to pending U.S. Provisional Patent ApplicationNo. 60/496,6221 the entire contents of which are incorporated byreference herein.

As noted above, the fastener product 500 can be produced using methodsand apparatuses similar to those discussed above with respect to FIGS. 2and 7. However, because the fastener projections 530 and the snapfeature 510 are formed on opposite surfaces of the base 515, one of themolding cavities and the molding recess are formed in the mold rollwhile the other is formed in the pressure roll.

Referring to FIGS. 10 and 11, in order to form the fastener product 500,the molding recesses 250 are defined by the pressure roll 220 and themolding cavities 252 are defined by the mold roll 215. For illustrativepurposes, the pressure roll 220, the mold roll 215, and the strippingroll 225 are separated from one another by greater distances than theywould be during actual use. Alternatively, the mold roll can, define themolding cavities and the pressure roll can define the molding recesses.The molding recesses 250 are arcuate-shaped depressions arrangedconcentrically in groups of four. The size and spacing of the recesses250 is dependent up on the intended purpose of the product. For example,if the product is intended to retain a compact disc, then the recesses250 will be sized and shaped to fit the mounting hole of the disc. Thecavities 252 can be of any suitable shape capable of forming fastenerprojections to engage an intended material. As discussed above, thecavities 252 are commonly hook-shaped, mushroom-shaped, orflat-top-shaped.

Referring to FIGS. 2 and 7, when the molten resin 230 is introduced intothe pressure nip 235, the pressure forces some of the resin into therecesses 250 within the mold roll 215 to form the snap features 510 andsome of the resin 230 is pressed into the cavities 252 within thepressure roll 220 to form the fastener elements 530. The remainder ofthe resin 230 is compressed between peripheral surfaces of the rolls215, 220 to form the base 515 from which the snap feature 510 and thefastener elements 530 extend.

FIG. 12 shows a longitudinal section of a fastener product sheet 540formed by the method and apparatus described above with respect to FIGS.10 and 11. The continuous fastener product sheet 540 includes multiple,longitudinally separated snap features 510. The fastener product 540sheet can be separated into multiple, discrete fastener products usingany of the separating processes discussed above. In some embodiments,the fastener sheet 540 is die cut to form separable, circular regions500 as indicated in FIG. 13. In other embodiments, the sheet 540 can beseparated into regions having various other shapes. The sheet 540, diecut as shown, can be spooled for transport or even retail sale, thefinal consumer removing the products 500 as needed.

In use, the flexible base 515 of the product 500 of FIG. 9, as formed bythe roll-forming method described above, displays sufficient, effectiverigidity when secured to a rigid loop carrying surface, such asautomotive headliners or cubicle walls, to allow removal andinstallation of media discs on the snap features 510.

Referring to FIG. 13, another fastener product 600 capable of beingproduced by the above-described methods includes a fastener strap 605and a head element 610. The fastener strap 605 includes a base 615 fromwhich multiple fastener projections 630 extend. The fastener strap 605can have various different dimensions depending on its intended use. Forexample, the base 625 of the fastener strap 605 can have a thickness ofbetween about 0.005 inch and 0.030 inch. The strap 605 can have a lengthof between about 3 inches and 36 inches. The width of the strap canrange from about 0.25 inch and 1 inch. In some cases, it is beneficialto provide a relatively wide strap in order to broadly distribute theretaining load among the fastener product. Because the relatively widestrap broadly distributes the load, the fastener product is able towithstand more stress (e.g., sheer stress) than a similar product havinga thinner strap. Similarly, the strength of the strap increases as thethickness of the strap increases.

Referring to FIG. 15, the fastener projections 630 are in the shape ofwedges. More particularly, a first surface 631 of the fastenerprojections 630 is substantially flat and inclined at an angle α ofbetween about 10 degrees and 45 degrees relative to the planar base 615.A second surface 633 extends from the base 615 at a steeper angle ofincline φ of between about 45 degrees and 90 degrees relative to thebase 615. The second surface 633 joins the first surface 631 to form anapex 632. The apex can have an angle ω ranging from about 30 to 80degrees. The projections 630 extend to a height of between about 0.01inch and 0.05 inch above the base 615. The fastener projections 630 arearranged such that the second surfaces 633 all face in the samedirection. In this case, the second sides 633 face toward the headelement 610.

The dimensions discussed, above are merely used to describe particularembodiments. Straps and projections of other suitable shapes and sizescapable of providing the product with fastening ability can be used.

Fastener projections having other shapes can also be employed. Referringto FIG. 14, for example, a fastener product 600A includes an array ofarcuate engageable elements 630A integrally molded with and extendingoutwardly from a base 615A. The engageable elements each include anengageable side 633A and a non-engageable side 631A. The engageable sideis inclined relative to the base at between about 5 degrees and 45degrees. The non-engageable side 631A is inclined relative to the baseat a steeper angle. The sides 633A, 631A join to form an apex 632A. Theengageable side 633A is defined by an upper edge and a lower edge wherethe engageable element intersects the base 615A. Both the upper andlower edges define curves (e.g., circular curves) such that theengageable side 633A has a curved shape. For more information regardingpossible fastener projection shapes, the reader is referred to pendingU.S. Patent Application Publication No. US 2005-0183248 A1, entitled“Shear Fasteners,” the entire contents of which are incorporated byreference herein.

Referring to FIGS. 13 and 15, the head element 610 defines an aperture645. When the fastener strap 605 is inserted through the aperture 645,the head element 610 cooperates with the fastener projections 630 toprevent the strap 605 from retreating back through the aperture 645. Inother words, the head element 610 is configured such that it providesone-way movement of the strap 605 through the aperture 645.

The head element 610 includes a retaining arm 658 that extends into theaperture 645. When the strap 605 is pulled through the aperture 645 inthe direction of the arrow, the first surfaces 631 of the wedge-shapedfastener projections 630 deflect the retaining arm 658 away from theprojections 630 allowing the strap 605 to proceed through the headelement 610. However, when the strap 605 is pulled in a directionopposite to that shown by the arrow, the second surface 633 of theprojection 630 abuts and engages the retaining arm 658. This preventsthe strap 605 from exiting the head element 610.

In particular embodiments, the head element 610 extends to a height ofbetween about 0.1 inch (0.254 cm) and 0.4 inch (1.016 cm) above the base615. Depending on the width of the strap 605, the width of the head canrange from about 0.3 inch (0.762 cm) to 1.25 inch (3.175 cm). Headelements, of other shapes and sizes capable of receiving the strap inthe aperture to allow the strap to enclose the product in a fastenedposition can be used.

Referring to FIG. 15A, the retaining arm 658 is integrally joined to therest of the structure of the head element 610 only at its base, suchthat it is able to flex away from the projections 630 during fastening.This allows the projections 630 to deflect the arm 658 as the strap 605is pulled through the hole 645, as discussed above. Other configurationscan be employed to provide the aim 658 with flexibility. A gap 659 isprovided between the arm 658 and the side of the head element 610. Insome embodiments, the gap 659 can be used to align guide rails of thestrap.

Referring to FIG. 15B, the retaining arm 658 can be configured to allowa user of the product 610 to release the arm 658 from engagement withthe projection 630 to allow the strap 605 to be removed from the headelement 610 after insertion. The retaining arm 658 includes an integralextension 657 that extends from the hole 645 beyond the head element610. When the product 606 is in its engaged position, the user candirect the distal rim of the extension 657 away from the strap 605 inorder to release the arm 658 from engagement with the projection 630.While doing this, the user can pull the strap 605 backthrough the hole645 in the direction opposite the arrow. Once the strap 605 has beenpulled completely through the hole 645, the product 600 once again takesthe form shown in FIG. 13. The above-described configuration enables theuser to reuse the fastener product 610 multiple times. Otherarrangements are also contemplated for enabling the user to release thearm 658 from engagement with the projection 630.

Referring to FIG. 13A, the fastener product 600 includes a backingmaterial 612 attached to a bottom surface of the strap 605 opposite thesurface from which the fastener projections 630 extend. The backingmaterial can be one of various suitable materials including, forexample, non-woven materials, knit materials, foam materials, andmetallized film. Depending on the material from which the backingmaterial 612 is composed, fit can provide various benefits, as discussedabove.

FIG. 16 shows a fastener product 650 that is similar to the product 600described above. The fastener product 650 includes guide rails 607, 609extending from the strap 605 on each side of the fastener projections630. The guide rails 607, 609 can be configured to correspond with gaps659 (shown in FIG. 15A) defined within the head element 610 at eitherend of the arm 658 to properly align the strap 605 as it is pulledthrough the aperture 645 of the head element 610. The guide rails 607,609 can also help to prevent the projections from engaging withunintended objects. The strap 605 could be accidentally pulled tighterthan desired, for example, if exposed ends of the projections 630 werecaught on an unintended object.

The fastener products shown in FIGS. 13, 14 and 16 can be utilized inmany of the same ways as discussed above with respect to the fastenerproduct shown in FIG. 1. For example, they can be used to retainarticles (e.g., wires, tubes, or pipes) in a bundle. Similarly, they canbe used to suspend an article or articles from a beam or otherstructure. In addition, the fastener products 600, 650 can be useful asa human restraint mechanism (e.g., handcuffs). They can be wrappedaround the wrists or ankles of a person and tightly fastened to restrainthe person.

Referring to FIG. 17 a method and apparatus similar to the methods andapparatuses illustrated in FIGS. 2, 7 and 8 can be used to produce theabove-described fastener products shown in FIGS. 13, 14 and 16. In thisembodiment, the mold roll 215 includes multiple lanes of moldingcavities 252 arranged across its transverse direction. Each lane ofmolding cavities is circumferentially separated along the mold roll 215such that the fastener product sheet molded in the process includesmultiple, longitudinally separated lanes of fastener projections. Inother embodiments, the mold roll can include a continuous array ofmolding cavities spanning the circumferential surface of the mold roll.The mold roll 215 also includes multiple, circumferentially spacedmolding recesses 250. As a result, the fastener product sheet molded inthe process includes multiple, longitudinally spaced apart head elementsand/or holes defined by the head elements.

Referring to FIG. 18, the mold roll 215 includes wedge-shaped moldingcavities 252 to mold wedge-shaped fastener projections. The cavities 252include a first planar surface that extends inward from the peripheralsurface of the mold roll 215 at a decline relative to the peripheralsurface. The cavities 252 include a second surface that extends inwardat a decline substantially steeper than the decline of the firstsurface. The first and second surfaces join together at their distalends within the cavities 252. In some embodiments, the second surface iscurved to form a projection having a curved wall.

The molding recesses 250 include an outer recessed portion 271 to formthe head element and an inner unrecessed portion 272 to form the holewithin the head element. The inner unrecessed portion 272 includes arecess 273 that extends inward at an angle relative to the side surfacesof the head elements for forming the restraining arm that extends fromthe head element.

In the embodiment discussed above, the molding cavities 252 and recesses250 are each located in the mold roll 215. In alternative embodiments,the pressure roll 220 can define the molding recesses 250 and cavities252. Similarly, the recesses 250 and cavities 252 can be located, invarious combinations, in both the mold roll 215 and the pressure roll220.

Referring to FIGS. 19 and 20, a fastener product sheet 640 formed usingthe method and apparatus shown in FIG. 17 includes a central region 655and two end regions 660, 665. The central region 655 includes a base 615from which multiple horizontal lanes of fastener projections 630 extend.The edge regions 660, 665 include longitudinally spaced head elements610 that define longitudinally spaced holes or apertures 645. Thefastener product sheet 640 can be separated along predeterminedfrangible boundaries 699 (e.g., perforated regions) to create multiple,discrete fastener products similar to the fastener products 600, 650shown in FIGS. 14 and 16. Any of the separating methods discussed abovecan be used to create the discrete fastener products.

FIGS. 21 and 22 illustrate an alternative mold roll 715 that can be usedwith any of the above-described methods to mold the discrete fastenerproducts described above with respect to FIGS. 13, 14, and 16. The moldroll 715 includes multiple lanes of molding cavities 252 extending alongits circumferential surface, a slot 795 that longitudinally separatesthe lanes of fastener projections 252, and an insert 790 retained withinthe slot 795. The molding cavities 252 are arranged in multiple lanesalong the circumference of the mold roll, rather than the transversedirection of the mold roll as shown in FIGS. 17 and 18. Other than theirorientation along the peripheral surface of the mold roll 715, thecavities 252 are identical to those described above with respect toFIGS. 17 and 18.

The insert 790 defines multiple molding recesses 250. Various suitablemethods of retaining the insert 790 within the slot 795 can be employed.For example, the insert 7901 can be press fitted within the slot 795.

The molding recesses 250 are arranged in the insert 790 such that thewidth of the molding recesses 250 extends across the transversedirection of the mold roll 215, rather than the circumferentialdirection as shown in FIGS. 17 and 18, when the insert 790 is securedwithin the slot 795. Other than their orientation along the peripheralsurface of the mold roll 715, the recesses 250 are identical to thoseshown in FIGS. 17 and 18.

Referring to FIG. 26, when implemented into one of the methods andapparatuses described above, the mold roll produces a fastener productsheet 740 that is similar to the sheet 640 shown in FIGS. 19 and 20.However, the lengths of the discrete fastener products 700 are alignedlongitudinally along the sheet 740, rather than transversely. The sheetcan 740 be separated into the multiple discrete fastener products 700using any of the methods described above. The sheet can be cut in boththe longitudinal and transverse directions to create discrete fastenerproducts. Alternatively, the sheet 740 can be cut only along its lengthto produce multiple, continuous lengths of longitudinally connectedfastener products 700, as shown in FIG. 27, that can be spooled fortransportation or retail packaging, for example. The sheet 740 can alsobe perforated between the longitudinally connected fastener products 700to allow them to be easily separated into multiple discrete fastenerproducts by a user.

Referring again to FIGS. 21 and 22, the inserts can be interchangeablyused in multiple different mold rolls. This can be beneficial formolding straps of different lengths. For example, a mold roll equippedwith only one slot for receiving the insert will produce a longer strapthan a similarly sized mold roll having multiple slots. Additionally, itis more cost-efficient to provide interchangeable inserts than toprovide multiple different mold rolls that define molding recesses invarious arrangements.

Other similar fastener products can be molded using the methods andapparatuses discussed above. Referring to FIG. 23, for example, afastener product 800 includes a tag 820 extending from a head element810. The fastener product 800 can be made using any off the methodsdiscussed above. An area of the mold roll and pressure roll adjacent themolding recess, which forms the head element 810, can include arelatively smooth portion (i.e., no recesses or cavities) to form thetag 820. The tag 820 can be used to indicate the contents of a bundleretained by the product or the contents of a bag that has been sealedusing the product 800, for example. The tag 820 can also be providedwith a bar code or an RFID label.

Referring to FIG. 24, a fastener product 850 similarly includes the tag820. The tag 820 defines an aperture 825, which can be used to hang theproduct 850 from a hook, for example. The product 850 can be formedusing any of the methods discussed above. The aperture 825 can either bemolded by a protruding section of the mold roll and/or pressure roll, orit can be cutout by the separating device. Alternatively, the product850 can be used to retain and secure bundles of wires within electricalboxes, for example. After being wrapped about a bundle of wires a screwor rivet can be inserted through the aperture 825 and attached to aninner wall of the electrical box to secure the product 850 and the wiresto the electrical box.

Referring to FIG. 25, a fastener product 900 includes a relatively flathead element 910 defining a slot 925. The fastener product 900 operatesin a similar manner to the fastener products 600, 650 described abovewith respect to FIGS. 14 and 16. During use, the free end 955 of thestrap 905 is inserted through the slot 925 of the head element 910. Thefastener projections 930 are arranged such that a first surface of theprojections 930 deflects the head element 910 in a region defining theslot 925, which allows the strap 905 to be pulled through the slot 925in one direction. If the strap 905 is pulled through the slot 925 in theopposite direction, a second surface of the projection 930 engages withthe head element 910 to impede movement of the strap 905 in thatdirection.

A user may release engagement of the projection 930 by bending the headelement 910 back toward the free end of the strap 905, and pulling thestrap 905 back through the head element 910. When the head element 910is bent toward the free end of the strap 905, its angle relative to theprojection 930 changes. This allows the head element 910 to disengagethe projection 930. As a result the user can pull the strap 905 backthrough the head element 910.

The product 900 can be formed using a method similar to those methodsdescribed above. In order to mold the fastener product 900, the moldroll and the pressure roll can include substantially smooth surfaces inthe region in which the flat head element 910 is formed, rather than arecess as described in the methods above. The slot can be created by theseparating device, such as by die cutting, or by a relatively sharpprotrusion extending from the mold roll and/or the pressure roll. Othersuitable means for creating the slot are also contemplated.

As shown in FIG. 36, a fastener product 1200 includes a strap 1205 and arelatively flat head element 1210 defining a slot 1225. The head element1210, like the strap 1205, includes projections 1230 extending from itssurface. During use, the fastener product 1200 operates similarly to thefastener product described above with respect to FIG. 25. In particular,the free end 1255 of the strap 1205 is inserted through the slot 1225defined by the head element 1210. The fastener projections 1230 arearranged such that a first surface of the projections 1230 deflects thehead element 1210 in a region defining the slot 1225, which allows thestrap 1205 to be pulled through the slot 1225 in one direction. If thestrap 1205 is pulled in the opposite direction, a second surface of theprojection 1230 engages with the head element 1210 to impede movement ofthe strap 1205 in that direction.

As discussed above with respect to the fastener product of FIG. 25, theuser may release engagement of the projection 1230 by bending the headelement 1210 back toward the free end of the strap 1205 and pulling thestrap 1205 back through the slot 1225 of the head element 1210.

The fastener product 1200 can be produced using any of various methodssimilar to those illustrated and described above. The mold roll andpressure roll used in this embodiment do not include molding recessesfor forming head elements. Rather, the mold roll and/or the pressureroll used to from the fastener product 1200 include substantiallycontinuous lanes of molding cavities for forming the projections 1230.As a result, a fastener product sheet having substantially continuousrows of projections is produced.

FIG. 37 shows a fastener product sheet 1300 produced by the processdescribed above. The fastener product sheet 1300 includes multiplelongitudinal lanes of the projections 1230. Separation lines 1301 havebeen added to show regions where the fastener product sheet 1300 can beseparated into multiple fastener products.

Any of the methods described above can be used to separate the fastenerproduct sheet 1300 into multiple fastener products. Similarly, the slots1225 can be created by any of the various suitable separation methodsdescribed above. For example, the fastener products and slots can becreated by die cutting, or by a relatively sharp protrusion extendingfrom the mold roll and/or the pressure roll. Other suitable means forcreating the fastener products and the slots are also contemplated. Asshown in FIG. 37, cuts are made through the base 1215 and theprojections 1230 to form the slots 1225. In other embodiments however,cuts can be positioned between the projections 1230 such that only thebase 1215 defines the slot 1225.

Because the fastener product sheet 1300 includes continuous rows of theprojections 1230, fastener products 1200 of various different sizes andshapes can be created. For example, the separating mechanism can beadjusted to cut fastener products having various different lengthswithout having to adjust other components used in the molding process.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.Accordingly, other embodiments are within the scope of the followingclaims.

1. A fastener product comprising: an elongate strap comprising a firstend and a second end; an array of projections molded of resinencapsulating features of the strap in a first region; a head elementmolded of resin encapsulating features of the strap in a second region,the head element defining a hole sized, to receive the second end of thestrap; and a backing material permanently attached to and overlying aback surface of the strap.
 2. The fastener product of claim 1, whereinthe strap comprises a continuous resin layer interconnecting theprojections and the head element.
 3. The fastener product of claim 1,wherein the head element has a thickness greater than a thickness of thestrap.
 4. The fastener product of claim 1, wherein the head element andthe strap form a unitary structure of molded resin.
 5. The fastenerproduct of claim 1, wherein the head element comprises a retaining armconfigured to engage at least one of the projections when the second endof the strap is pulled in a first direction through the hole defined bythe head element the retaining arm being configured to allow the strapto be pulled in the first direction through the hole defined by the headelement and to deter the strap from being pulled in a second directionopposite the first direction through the hole defined by the headelement.
 6. The fastener product of claim 1, wherein the strap comprisesat least one resin region permanently attached to the backing material.7. The fastener product of claim 6, wherein the projections extend fromthe at least one resin region.
 8. The fastener product of claim 1,wherein the projections comprise a stem portion and a head portion, thehead portion overlying the strap.
 9. The fastener product of claim 1,wherein at least some of the projections comprise a wedge with an uppersurface extending from the strap at an angle of about 5 degrees to about45 degrees and terminating in a raised distal edge.
 10. The fastenerproduct of claim 9, wherein multiple wedges are longitudinally spacedapart along the strap.
 11. The fastener product of claim 9, wherein thestrap further defines a wide rail extending along the strap, the guiderail being arranged to cooperate with a gap defined by the head elementto align the strap in a desired position relative to the head elementwhen the strap is pulled through the hole defined by the head element.12. The fastener product of claim 1, further comprising a loop materialattached to a front surface of the strap.
 13. The fastener product ofclaim 12, wherein the projections comprise hooks configured, to engagethe loop material.
 14. The fastener product of claim 1, wherein thefastener product is part of a preform fastener product sheet comprisingmultiple fastener products, the sheet defining frangible parting linesbetween adjacent fastener products.
 15. A fastener product comprising:an elongate strap comprising a first end and a second end; an array offastener projections molded of resin encapsulating features of the strapin a first region; a head element molded of resin encapsulating featuresof the strap in a second region, the head element defining a hole sizedto receive the second end of the strap; and a resin band extendingtransversely across the strap in a discrete region spaced apart from thehead element, the resin band stiffening the product in the discreteregion.
 16. The fastener product of claim 15, wherein the strapcomprises a continuous resin layer interconnecting the projections, thehead element and the resin band.
 17. The fastener product of claim 15,wherein the resin band has a stiffness of at least 15 pounds per inch.18. The fastener product of claim 15, wherein the resin band and thestrap form a unitary structure of molded resin.
 19. The fastener productof claim 15, further comprising a loop material attached to the strap,and configured to engage the projections.
 20. The fastener product ofclaim 19, wherein the projections comprise hooks.
 21. The fastenerproduct of claim 15, wherein the strap comprises at least one resinregion permanently attached to a backing material.
 22. The fastenerproduct of claim 21, wherein the projections extend from the at leastone resin region.
 23. The fastener product of claim 21, wherein the headelement extends from the at least one resin region.
 24. The fastenerproduct of claim 15, wherein the projections comprise, a stem portionand a head portion overlying the strap.
 25. The fastener product ofclaim 24, wherein the head portion comprises a distal end extendingdownward toward the strap.
 26. The fastener product of claim 15, whereinthe resin band comprises a plurality of ribs.
 27. The fastener productof claim 15, further comprising a loop material attached to the strap.28. The fastener product of claim 27, wherein the projections comprisehooks configured to engage the loop material.
 29. The fastener productof claim 15, wherein the fastener product comprises a splint, and theresin band has sufficient stiffness to resist bending of a body partwrapped by the splint.
 30. The fastener product of claim 15, wherein thefastener product is part of a preform fastener product sheet comprisingmultiple fastener products, the sheet defining frangible parting linesbetween adjacent fastener products.
 31. A fastener product comprising:an elongate strap comprising a first resin region, a second resinregion, and a backlog material permanently attached to the first andsecond resin regions; a plurality of projections molded of resin, theprojections being integrally molded with the first region of the strap;and a head element molded of resin, the head element being integrallymolded with the second region of the strap, the head element defining ahole sized to receive a free end of the strap.
 32. The fastener productof claim 31, wherein the strap comprises a continuous resin layerinterconnecting the projections and the head element.
 33. The fastenerproduct of claim 31, wherein the head element comprises a retaining armconfigured to engage at least one of the projections when the second endof the strap is pulled in a first direction through the hole defined bythe head element, the retaining arm being configured to allow the strapto be pulled in the first direction through the hole defined by the headelement and to deter the strap from being pulled in a second directionopposite the first direction through the hole defined by the headelement.
 34. The fastener product of claim 31, wherein at least some ofthe projections comprise a wedge with an upper surface extending fromthe strap at an angle of about 5 degrees to about 45 degrees and,terminating in a raised distal edge.
 35. The fastener product of claim31, wherein the fastener product is part of a preform fastener productsheet comprising multiple fastener products, the sheet definingfrangible parting lines between adjacent fastener products.
 36. Afastener product comprising: an elongate strap comprising a first resinregion and a second resin region; an array of fastener projectionsmolded of resin, the fastener projections being integrally molded withthe first resin region; a head element molded of resin, the head elementbeing integrally molded with the second region of the strap, the headelement defining a hole sized to receive a free end of the strap; and aresin band extending transversely across the strap in a discrete regionspaced apart from the head element, the resin band stiffening theproduct, in the discrete region.
 37. The fastener product of claim 36,wherein the strap comprises a continuous resin layer interconnecting theprojections, the head element, and the resin band.
 38. The fastenerproduct of claim 36, wherein the resin band and the strap form a unitarystructure of molded resin.
 39. The fastener product of claim 36, whereinthe fastener product comprises a splint, and the resin band hassufficient stiffness to resist bending of a body part wrapped by thesplint.
 40. The fastener product of claim 36, wherein the fastenerproduct is part of a preform fastener product sheet comprising multiplefastener products, the sheet defining frangible parting lines betweenadjacent fastener products.